Skin cleansing bar with high levels of liquid emollient

ABSTRACT

A low water content cleansing composition in toilet bar form is described which includes high levels of emollients having a melting point below 25 C, 12-hydroxystearic acid as a structuring agent, and at least one detersive surfactant. Useful emollients that are liquid at room temperature may include triglycerides, petroleum oil, polyhydric alcohols and silicone oil, and are present in a concentration range of 5 to 60 wt. %. The inventive toilet bars have excellent mush and wear properties.

[0001] This application claims priority to U.S. provisional applicationserial No. 60/257,222 filed Dec. 21, 2000.

BACKGROUND OF THE INVENTION

[0002] This invention relates generally to cleansing bars, and moreparticularly to cleansing bars having high levels of emollient.

[0003] Synthetic detergent or syndet toilet bars have found considerableuse as mild cleansing bars but such bars have the potential to be softand typically require structuring agents to be added to firm or hardenthe bar. Thus the main function of prior art structurants such as sodiumstearate in syndet bars is to provide body and give structure to theproduct. For example, sodium stearate finds considerable use as astructurant or structuring agent in syndet bar formulations, forming afibrous network structure which helps in improving the mush and rate ofwear properties of the bars. However, there is a problem in structuringsyndet bars containing high levels of emollients that are liquid at roomtemperature (25 C).

[0004] 12-Hydroxystearic acid has been previously employed as astrucuturing agent in high water content soap or syndet bars; see e.g.U.S. Pat. No. 5,225,097 issued to M. Kacher, et al. on Jul. 6, 1993 andU.S. Pat. No.5,227,086 issued to M. Kacher, et al. on Jul. 13,1993;which are herein incorporated by reference. However the bars describedby Kacher did not contain high levels of hydrophobic or hydrophilicemollients which have melting points below 25 C. J P Kokai publicationno. 7034100A, issued to E. Yoshiyuki, et al. on Feb. 3,1995 describes asyndet bar containing 1 to 30% by weight of a liquid or semi-solid oiland 0.01 to 5% by weight of 12-hydroxystearic acid. However, thephysical properties of the bars described by Yoshiyuki are notcommercially acceptable, especially regarding the bar's wear rate andmush properties.

[0005] Unexpectedly the use of 12-hydroxystearic acid in syndetformulations at levels in excess of 5% by weight and with high levels ofemollients that are liquid at room temperature (i.e. have a meltingpoint below 25 C) has been found to substantially improve the rate ofwear and mush propensity of syndet toilet bars. High rates of wear andmush propensity are negative attributes of prior art syndet formulationsas discussed above.

[0006] Furthermore it was unexpectedly discovered that the use of12-hydroxy stearic acid in a low viscosity melt (Brookfield viscosityrange of about 10 cps to about 40,000 cps) with high amounts ofemollients which are liquid at room temperature gave a relatively stablemelt, with no observable phase separation, between 70° C. and 110° C.with continuous mixing. In comparison, the same quantity of stearic acidas the sole structuring agent yields a very unstable syndet bar systemwhere the hydrophobic emollient phase noticeably separates from the mixin the absence of phase stabilizers such as lauryl alcohol, oralternatively produces an undesirably soft bar in the absence of phaseseparation. It was also unexpectedly found that the use of12-hydroxystearic acid in syndet formulations will improve the rate ofwear and mush propensity of the formulations.

SUMMARY OF THE INVENTION

[0007] In one aspect, the present invention relates to a mild toilet barwith high levels of hydrophobic or hydrophilic emollients have a meltingpoint below 25 C. and having 12-hydroxystearic acid as one of itsstructuring agents at a level above 5% by weight. Preferably,12-hydroxystearic acid is the primary structuring agent present. Mostpreferably, 12-hydroxystearic acid is the sole structuring agentpresent.

[0008] Conventional structuring agents preferably are present in theinventive bar in the concentration range of about 5 to about 30% byweight. In the case where 12-hydroxystearic acid is the sole structuringagent, it is present in the concentration range of about 10 to 15%,preferably about 13 to 15% by weight.

[0009] In another aspect, the inventive toilet bar is mildly acidic toneutral having a pH range of about 5.0 to 7.0, preferably 5.0 to 6.0,and most preferably 5.3 to 5.7.

[0010] In a further aspect, the inventive toilet bar has a low moisturecontent, in the range of about 1 to less than about 15% by weight ofwater; preferably in the range of about 2 to about 13% by weight ofwater, and most preferably in the range of about 2 to about 6% by weightof water.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011]FIG. 1 is a graph depicting the relationship of yield stressversus the concentration of 12-hydroxystearic acid (HSA) in theinventive toilet bar.

[0012]FIG. 2 is a graph depicting the relationship of mush versus theconcentration of 12-hydroxystearic acid (HSA) in the inventive toiletbar.

[0013]FIG. 3 is a graph depicting the relationship of wear rate versusthe concentration of 12-hydroxystearic acid (HSA) in the inventivetoilet bar.

DETAILED DESCRIPTION OF THE INVENTION:

[0014] In one aspect, the present invention relates to a mild toilet barcomprising:

[0015] (i) about 5 to 60% by weight of a liquid emollient with a meltingpoint below 25 C.;

[0016] (ii) about 15% to 60% by weight of a surfactant; and

[0017] (iii) more than about 5% by weight of 12-hydroxystearic acid,wherein the ratio of said 12-hydroxystearic acid to said liquidemollient is in the range of about 1 to 5 to about 10 to 1.

[0018] As used herein, the term liquid emollient refers to an emollientthat is flowable at 25 C prior to being blended in the cleansingcomposition. Similarly, the term solid emollent refers to an emollientthat does not flow at 25 C prior to being blended in the cleansingcomposition.

[0019] Preferably the inventive composition has a ratio of12-hydroxystearic acid to liquid emollient in the range of about 1 to 5to about 2 to 1. The liquid emollient is selected from hydrophillic andhydrophobic liquid emollients, and blends thereof. Preferably the liquidhydrophilic emollient is present in the concentration range of about 2to 20% by weight, more preferably about 5 to 10% by weight. Preferablythe liquid hydrophobic emollient is present in the concentration rangeof about 2 to 45% by weight, more preferably about 10 to 30% by weight.Useful hydrophilic liquid emollients are selected from polyhydricalcohols, polyols, saccharides, and mixtures thereof. Useful hydrophobicliquid emollients are selected from triglycerides, hydrocarbons,silicones, fatty acids, fatty, esters, fatty alcohols, and blendsthereof.

[0020] The inventive composition preferably contains 12-hydroxystearicacid in the range of about 5 to 20% by weight, more preferably about 10to about 15% by weight. The inventive composition preferably includes atleast one acyl isethionate, preferably in the concentration range ofabout 5 to about 45% by weight of total acyl isethionates. Mostpreferably at least one of the acyl isethionates is sodium cocoylisethionate.

[0021] The inventive composition further comprises a solid emollient.Useful solid emollients are selected from the group of fatty acids,fatty esters, fatty alcohols, waxes, or triglycerides. Preferably thesolid emollient and liquid emollient is in the ratio range of about 1 to10 to about 10 to 1, more preferably in the range of about 1 to 5 toabout 1 to 2.

[0022] In another aspect of the invention a toilet bar composition isprovided comprising:

[0023] (i) about 5 to 60% by weight of a liquid emollient with a meltingpoint below 25 C.;

[0024] (ii) about 15% to 60% by weight of a surfactant;

[0025] (iii) more than about 5% by weight of 12-hydroxystearic acid,wherein the ratio of said 12-hydroxystearic acid to said emollient is inthe range of about 1 to 5 to about 10 to 1; and

[0026] (iv) less than about 15% by weight of water.

[0027] Preferably the ratio of 12-hydroxystearic acid to liquidemollient is in the range of about 1 to 5 to about 1 to 3. Preferablythe bar contains less than about 6% by weight of water.

[0028] In a further aspect of the invention, a toilet bar composition isprovided comprising:

[0029] a) about 5 to 60% by weight of a liquid emollient with a meltingpoint below 25 C.;

[0030] b) about 15% to 60% by weight of a surfactant;

[0031] c) more than about 5% by weight of 12-hydroxystearic acid,wherein the ratio of said 12-hydroxystearic acid to said liquidemollient is in the range of about 1 to 5 to about 10 to 1; and

[0032] d) a hydrophilic emollient, and a hydrophobic emollient; whereinthe ratio of said hydrophilic emollient and said hydrophobic emollientis in the range of about 1 to 10 to about 5 to 1.

[0033] The inventive toilet bar composition preferably has a ratio ofhydrophilic emollients to hydrophobic emollients in the range of about 1to 8 to about 1 to 5.

[0034] In a further aspect of the invention, a toilet bar composition isprovided comprising:

[0035] a) about 10 to 30% by weight of a triglyceride liquid emollientwith an iodine value in the range of 80 to 140 and a melting point below25 C;

[0036] b) about 15 to 60% by weight of an acyl isethionate;

[0037] c) about 10 to 15% by weight of 12-hydroxystearic acid; and lessthan about 6% water.

[0038] In still a further aspect of the invention, a toilet barcomposition is provided comprising:

[0039] a) about 5 to 60% by weight of a hydrophobic liquid emollientwith a melting point below 25 C.;

[0040] b) about 15% to 60% by weight of a surfactant;

[0041] c) more than about 5% by weight of 12-hydroxystearic acid, andwherein the ratio of said surfactant to said hydrophobic liquidemollient is less than about 5 to 3.

[0042] Preferably the ratio of surfactant to hydrophobic liquidemollient is in the range of about 10 to 1 to about 1 to 3, morepreferably in the range of about 4 to 3 to about 1 to 2.

[0043] Preferably, 12-hydroxystearic acid is the primary structuringagent present in the inventive bar. Most preferably, 12-hydroxystearicacid is the sole structuring agent present. Conventional structuringagents preferably are present in the inventive bar in the concentrationrange of about 5 to about 30% by weight. In the case where12-hydroxystearic acid is the sole structuring agent, it is present inthe concentration range of about 10 to 15%, preferably about 13 to 15%by weight.

[0044] In another aspect, the inventive toilet bar is mildly acidic toneutral having a pH range of about 5.0 to 7.0, preferably 5.0 to 6.0,and most preferably 5.3 to 5.7.

[0045] In a further aspect, the inventive toilet bar has a low moisturecontent, in the range of about 1 to less than about 15% by weight ofwater; preferably in the range of about 2 to about 13% by weight ofwater, and most preferably in the range of about 2 to about 6% by weightof water.

[0046] Surfactants:

[0047] Surfactants are an essential component of the invenvtive toiletbar. They are compounds that have hydrophobic and hydrophilic portionsthat act to reduce the surface tension of the aqueous solutions they aredissolved in. Useful surfactants can include anionic, nonionic,amphoteric, and cationic surfactants, and blends thereof.

[0048] Anionic Surfactants:

[0049] The toilet bar of the present invention contains one or moreanionic detergents. The anionic detergent active which may be used maybe aliphatic sulfonates, such as a primary alkane (e.g., C₈-C₂₂)sulfonate, primary alkane (e.g., C₈-C₂₂) disulfonate, C₈-C₂₂ alkenesulfonate, C₈-C₂₂ hydroxyalkane sulfonate or alkyl glyceryl ethersulfonate (AGS); or aromatic sulfonates such as alkyl benzene sulfonate.

[0050] The anionic may also be an alkyl sulfate (e.g., C₁₂-C₁₈ alkylsulfate) or alkyl ether sulfate (including alkyl glyceryl ethersulfates). Among the alkyl ether sulfates are those having the formula:

RO(CH₂CH₂O)_(n)SO₃M

[0051] wherein R is an alkyl or alkenyl having 8 to 18 carbons,preferably 12 to 18 carbons, n has an average value of greater than 1.0,preferably greater than 3; and M is a solubilizing cation such assodium, potassium, ammonium or substituted ammonium. Ammonium and sodiumlauryl ether sulfates are preferred.

[0052] The anionic may also be alkyl sulfosuccinates (including mono-and dialkyl, e.g., C₆-C₂₂ sulfosuccinates); alkyl and acyl taurates,alkyl and acyl sarcosinates, sulfoacetates, C₈-C₂₂ alkyl phosphates andphosphates, alkyl phosphate esters and alkoxyl alkyl phosphate esters,acyl lactates, C₈-C₂₂ monoalkyl succinates and maleates, sulphoacetates,alkyl glucosides and acyl isethionates, and the like.

[0053] Sulfosuccinates may be monoalkyl sulfosuccinates having theformula:

R⁴O₂CCH₂CH(SO₃M)CO₂M; and

[0054] amide-MEA sulfosuccinates of the formula;

R⁴CONHCH₂CH₂O₂CCH₂CH(SO₃M)CO₂M

[0055] wherein R⁴ ranges from C₈-C₂₂ alkyl and M is a solubilizingcation.

[0056] Sarcosinates are generally indicated by the formula:

R¹CON(CH₃)CH₂CO₂M,

[0057] wherein R¹ ranges from C₈-C₂₀ alkyl and M is a solubilizingcation.

[0058] Taurates are generally identified by formula:

R²CONR³CH₂CH₂SO₃M

[0059] wherein R² ranges from C₈-C₂₀ alkyl, R³ ranges from C₁-C₄ alkyland M is a solubilizing cation.

[0060] The inventive bar contains anionic surfactants, preferablycontains C₈-C₁₈ acyl isethionates. These esters are prepared by reactionbetween alkali metal isethionate with mixed aliphatic fatty acids havingfrom 6 to 18 carbon atoms and an iodine value of less than 20. At least75% of the mixed fatty acids have from 12 to 18 carbon atoms and up to25% have from 6 to 10 carbon atoms.

[0061] Total surfactants will generally range from about 15% to about60% by weight of the toilet bar. Preferably, this component is presentfrom about 25% to about 40% in the bar.

[0062] The acyl isethionate may be an alkoxylated isethionate such as isdescribed in llardi et al., U.S. Pat. No. 5,393,466, titled “Fatty AcidEsters of Polyalkoxylated isethonic acid; issued Feb. 28, 1995; herebyincorporated by reference. This compound has the general formula:

[0063] wherein R is an alkyl group having 8 to 18 carbons, m is aninteger from 1 to 4, X and Y are hydrogen or an alkyl group having 1 to4 carbons and M⁺ is a monovalent cation such as, for example, sodium,potassium or ammonium.

[0064] It should be understood that the bar may comprise a certainamount of soap as anionic surfactant. When used, the term “soap” is usedin its popular sense, i.e., alkalimetal or alkanol ammonium salt ofaliphatic alkane or alkene monocarboxylic acids. Sodium, potassium,mono-, di- and triethanol ammonium cations, or combinations thereof, aresuitable for purposes of the invention. Generally, sodium soaps areused. Soaps useful herein are the well known alkali metal salts ofnatural or synthetic aliphatic (alkanoic or alkenoic) acids having 13 to22 cations, preferably 12 to 18. They may be described as alkali metalcarboxylates of acrylic hydrocarbons having about 12 to 22 carbons.

[0065] Anionic surfactants with Krafft points of up to 40 to 45 C can beused in the formulation. Anionic surfactants with a Krafft point belowroom temperature are preferred.

[0066] Amphoteric Surfactants

[0067] One or more amphoteric surfactants may be used in this invention.Such surfactants include at least one acid group. This may be acarboxylic or a sulphonic acid group. They include quaternary nitrogenand therefore are quaternary amido acids. They should generally includean alkyl or alkenyl group of 7 to 18 carbon atoms. They will usuallycomply with an overall structural formula:

[0068] where R¹ is alkyl or alkenyl of 7 to 18 carbon atoms;

[0069] R² and R³ are each independently alkyl, hydroxyalkyl orcarboxyalkyl of 1 to 3 carbon atoms;

[0070] n is 2 to 4;

[0071] m is 0 to 1;

[0072] X is alkylene of 1 to 3 carbon atoms optionally substituted withhydroxyl, and

[0073] Y is —CO₂— or —SO₃—

[0074] Suitable amphoteric surfactants within the above general formulainclude simple betaines of formula:

[0075] and amido betaines of formula:

[0076] where n is 2 or 3.

[0077] In both formulae R¹, R² and R³ are as defined previously. R¹ mayin particular be a mixture of C₁₂ and C₁₄ alkyl groups derived fromcoconut oil so that at least half, preferably at least three quarters ofthe groups R¹ have 10 to 14 carbon atoms. R² and R³ are preferablymethyl.

[0078] A further possibility is that the amphoteric detergent is asulphobetaine of formula:

[0079] where m is 2 or 3, or variants of these in which —(CH₂)₃ SO₃— isreplaced by

[0080] In these formulae R¹, R² and R³ are as discussed previously.

[0081] Nonionic Surfactants

[0082] One or more nonionic surfactants may also be used in the toiletbar of the present invention.

[0083] The nonionics which may be used include in particular thereaction products of compounds having a hydrophobic group and a reactivehydrogen atom, for example aliphatic alcohols, acids, amides oralkylphenols with alkylene oxides, especially ethylene oxide eitheralone or with propylene oxide. Specific nonionic detergent compounds arealkyl (C₆-C₂₂) phenols ethylene oxide condensates, the condensationproducts of aliphatic (C₈-C₁₈) primary or secondary linear or branchedalcohols with ethylene oxide, and products made by condensation ofethylene oxide with the reaction products of propylene oxide andethylenediamine. Other so-called nonionic detergent compounds includelong chain tertiary amine oxides, long chain tertiary phosphine oxidesand dialkyl sulphoxide, and the like.

[0084] The nonionic may also be a sugar amide, such as a polysaccharideamide. Specifically, the surfactant may be one of the lactobionamidesdescribed in U.S. Pat. No. 5,389,279 to Au et al. titled “CompositionsComprising Nonionic Glycolipid Surfactants issued Feb. 14, 1995; whichis hereby incorporated by reference or it may be one of the sugar amidesdescribed in U.S. Pat. No. 5,009,814 to Kelkenberg, titled “Use ofN-Poly Hydroxyalkyl Fatty Acid Amides as Thickening Agents for LiquidAqueous Surfactant Systems” issued Apr. 23, 1991; hereby incorporatedinto the subject application by reference.

[0085] Cationic Surfactants

[0086] One or more cationic surfactants may also be used in theinventive toilet bar.

[0087] Examples of cationic detergents are the quaternary ammoniumcompounds such as alkyldimethylammonium halogenides.

[0088] Other suitable surfactants which may be used are described inU.S. Pat. No. 3,723,325 to Parran Jr. titled “Detergent CompositionsContaining Particle Deposition Enhancing Agents” issued Mar., 27, 1973;and “Surface Active Agents and Detergents” (Vol. I & II) by Schwartz,Perry & Berch, both of which are also incorporated into the subjectapplication by reference.

[0089] Structuring Agents

[0090] The inventive toilet bar also contains 5 to 30% by wt.,preferably 10 to 15% by wt. of total structurant including12-hydroxystearic acid. Preferably the only structurant in the toiletbar is 12-hydroxystearic acid and is present at 10 to 15% by wt.,preferably at 11 to 15% by wt., and most preferably at 13 to 15% by wt.Structurants are used to enhance the bar integrity, improve theprocessing properties, and enhance desired user sensory profiles.Suitable co-structurants are generally long chain, preferably straightand saturated, (C₈-C₂₄) fatty acid or ester derivative thereof; and/orbranched long chain, preferably straight and saturated, (C₈-C₂₄) alcoholor ether derivatives thereof. These co-structurants are preferablypresent at a level which allows the pH of the bar to remain in the 5.5to 6.0 range. The pH of the formulation may be adjusted by incoproratingsodium or potassium salts of fatty acids. However, it is preferred notto neutralize 12-hydroxysteric acid when it is used as the solestructuring agent.

[0091] The inventive bar also optionally contains fillers selected frominorganic minerals such as calcium sulfate, and the like; and starches,preferably water soluble starches such as maltodextrin and the like andpolyethylene wax or paraffin wax, and the like. Fillers may be presentin the inventive toilet bar in the range of 1 to 15% by weight,preferably 1 to 5% by weight.

[0092] Other co-structuring aids can also be selected from water solublepolymers chemically modified with a hydrophobic moiety or moieties, forexample, EO-PO block copolymer, hydrophobically modified PEGs such asPOE(200)-glyceryl-stearate, glucam DOE 120 (PEG 120 Methyl GlucoseDioleate), and Hodag CSA-102 (PEG-150 stearate), and Rewoderm® (PEGmodified glyceryl cocoate, palmate or tallowate) from Rewo Chemicals.

[0093] Other co-structuring aids which may be used include AmercholPolymer HM 1500 (Nonoxynyl Hydroethyl Cellulose).

[0094] In addition, the inventive bar composition of the invention mayinclude 0 to 15% by wt. optional ingredients as follows:

[0095] perfumes; sequestering agents, such as tetrasodiumethylenediaminetetraacetate (EDTA), EHDP or mixtures in an amount of0.01 to 1%, preferably 0.01 to 0.05%; and coloring agents, opacifiersand pearlizers such as zinc stearate, magnesium stearate, TiO₂, EGMS(ethylene glycol monostearate) or Lytron 621 (Styrene/Acrylatecopolymer) and the like; all of which are useful in enhancing theappearance or cosmetic properties of the product.

[0096] The compositions may further comprise antimicrobials such as2-hydroxy-4,2′, 4′ trichlorodiphenylether (DP300); preservatives such asdimethyloldimethylhydantoin (Glydant XL1000), parabens, sorbic acidetc., and the like.

[0097] The compositions may also comprise coconut acyl mono- ordiethanol amides as suds boosters, and strongly ionizing salts such assodium chloride and sodium sulfate may also be used to advantage.

[0098] Antioxidants such as, for example, butylated hydroxytoluene (BHT)and the like may be used advantageously in amounts of about 0.01% orhigher if appropriate.

[0099] Cationic polymers as conditioners which may be used includeQuatrisoft LM-200 Polyquaternium-24, Merquat Plus 3330- Polyquaternium39; and Jaguar® type conditioners. Polyethylene glycols as conditionerswhich may be used include: Polyox WSR-205 PEG 14 M, Polyox WSR-N-60K PEG45 M, or Polyox WSR-N-750 PEG 7 M.

[0100] Another ingredient which may be included are exfoliants such aspolyoxyethylene beads, walnut shells and apricot seeds, and the like.

[0101] Compositions of the inventive toilet bar also comprise 1% to 13%by wt., preferably 2% to 6% by wt. water.

[0102] In one embodiment of the invention, the inventive toilet bar'scomposition comprises no more than about 60% surfactant and preferablyin the range of 20 to 60% by weight.

[0103] The emollient “composition” may be a single benefit agentcomponent or it may be a benefit agent compound added via a carrier.Further the benefit agent composition may be a mixture of two or morecompounds one or all of which may have a beneficial aspect. In addition,the benefit agent itself may act as a carrier for other components onemay wish to add to the bar composition.

[0104] The benefit agent can be either a hydrophobic or hydrophilicemollient or a blend thereof. Preferably one or more hydrophobicemollients are used either alone, or together with one or morehydrophilic emollients. Most preferably, hydrophobic emollients are usedin excess of hydrophilic emollients in the inventive bar. Hydrophobicemollients are preferably present in the concentration range of about 5to 45% by weight, preferably 10 to 25% by weight. Hydrophillicemollients may preferably be present in the concentration range of 5 to20% by weight. The term “emollient” is defined as a substance whichsoftens or improves the elasticity, appearance, and youthfulness of theskin (stratum corneum) by either increasing its water content, adding,or replacing lipids and other skin nutrients; or both, and keeps it softby retarding the decrease of its water content. Emollients which areeither solid or liquid at 25 C may be used individually or as a blend ofemollients with melting points above and below 25 C. These emollientsare present in the concentration range of about 5 to 60% by weight. Itis preferred that at least one emollient has a melting point below 25 CPreferably the total low melting emollients are present in theconcentration range of about 20 to 35% by weight and is hydrophobic.

[0105] Useful emollients include the following:

[0106] (a) silicone oils and modifications thereof such as linear andcyclic polydimethylsiloxanes; amino, alkyl, alkylaryl, and aryl siliconeoils;

[0107] (b) fats and oils including natural fats and oils such as jojoba,soybean, sunflower, rice bran, avocado, almond, olive, sesame, persic,castor, coconut, mink oils; cacao fat; beef tallow, lard; hardened oilsobtained by hydrogenating the aforementioned oils; and synthetic mono,di and triglycerides such as myristic acid glyceride and 2-ethylhexanoicacid glyceride;

[0108] (c) waxes such as carnauba, spermaceti, beeswax, lanolin, andderivatives thereof;

[0109] (d) hydrophobic plant extracts;

[0110] (e) hydrocarbons such as liquid paraffins, vaseline,microcrystalline wax, ceresin, squalene, pristan and mineral oil;

[0111] (f) higher fatty acids such as lauric, myristic, palmitic,stearic, behenic, oleic, linoleic, linolenic, lanolic, isostearic,arachidonic and poly unsaturated fatty acids (PUFA);

[0112] (g) higher alcohols such as lauryl, cetyl, stearyl, oleyl,behenyl, cholesterol and 2-hexydecanol alcohol;

[0113] (h) esters such as cetyl octanoate, myristyl lactate, cetyllactate, isopropyl myristate, myristyl myristate, isopropyl palmitate,isopropyl adipate, butyl stearate, decyl oleate, cholesterolisostearate, glycerol monostearate, glycerol distearate, glyceroltristearate, alkyl lactate, alkyl citrate and alkyl tartrate;

[0114] (i) essential oils and extracts thereof such as mentha, jasmine,camphor, white cedar, bitter orange peel, ryu, turpentine, cinnamon,bergamot, citrus unshiu, calamus, pine, lavender, bay, clove, hiba,eucalyptus, lemon, starflower, thyme, peppermint, rose, sage, sesame,ginger, basil, juniper, lemon grass, rosemary, rosewood, avocado, grape,grapeseed, myrrh, cucumber, watercress, calendula, elder flower,geranium, linden blossom, amaranth, seaweed, ginko, ginseng, carrot,guarana, tea tree, jojoba, comfrey, oatmeal, cocoa, neroli, vanilla,green tea, penny royal, aloe vera, menthol, cineole, eugenol, citral,citronelle, borneol, linalool, geraniol, evening primrose, camphor,thymol, spirantol, penene, limonene and terpenoid oils;

[0115] (j) lipids such as cholesterol, ceramides, sucrose esters andpseudo-ceramides as described in European Patent Specification No.556,957;

[0116] (k) vitamins, minerals, and skin nutrients such as vitamins A, E,and K; vitamin alkyl esters, including vitamin C alkyl esters;magnesium, calcium, and milk.

[0117] (l) sunscreens such as octyl methoxyl cinnamate (Parsol MCX) andbutyl methoxy benzoylmethane (Parsol 1789);

[0118] (l) phospholipids;

[0119] (m) polyhydric alcohols such as glycerine and propylene glycol;and polyols such as polyethylene glycols,

[0120] (n) antiaging compounds such as alpha hydroxy acids, beta hydroxyacids; and

[0121] (o) mixtures of any of the foregoing components, and the like.

[0122] Preferred emollient benefit agents are selected from triglycerideoils, petroleum oils, polyhydric alcohols and silicone oils. Morepreferably sunflower seed oil, propylene glycol and glycerin are used.Further preferred emollients are triglycerides having an iodine valuefrom about 50 to about 145, with a range of about 80 to about 130 beingespecially preferred.

[0123] The composition may also comprise decorative or functionalparticulates including speckles, coloured or reflective particles, orshaped particles, encapsulated beads, sponge, and the like.

[0124] Conventional art recognised melt cast processing techniques maybe used to fabricate the inventive toilet bar. For example, the meltedcomponents of the inventive bar are usually blended together at elevatedtemperatures. Optionally the water level may be adjusted and theblending will continue. Next an optional drying step may follow wherebythe water is reduced. Preferably the water level of the ingredients isselected to be low enough to avoid the drying process. Finally, themolten cleansing composition is poured into molds and cooled to itshardening point. The molds may be made of any rigid material that is notsubject to attack by the ingredients of the toilet bar. Mold materialsmay include plastic, metal, glass, ceramic, composite, or elastomericmaterials and the like. Cooling the molten cleansing materials can beaccomplished by art recognised cooling techniques includingrefrigeration, cryogenics, ambient air and the like. Controlled coolingusing thermostatic control cooling devices may also be employed.

[0125] Conventional art recognised packaging materials may be used topackage the inventive toilet bar. The package may hold one or moreseparately packaged bars. The package may also have an optionaltransparent area to view part or all of the bar contained therein.Paper, plastic, or coated paper, or other flexible or rigid packagingmaterials that are compatible with the toilet bar may be used. Singlelayer or laminated packaging material structures may also be used.Preferably, the packaging material is moisture proof, and moldresistant. The packaging material should have good barrier properties toprevent the loss of volatile cleansing composition ingredients such asperfume. Examples, of useful barrier materials are polymer coated paperboard or other appropriate materials. Hot melt adhesive or contactadhesive such as glue may be used to adhere a portion of the carton andthe wrapper. An appropriate coating would be a low density polyethylenecoating and the like.

[0126] Except in the operating and comparative examples, or whereotherwise explicitly indicated, all numbers in this descriptionindicating amounts of material ought to be understood as modified by theword “about”.

[0127] The following examples will more fully illustrate the embodimentsof this invention. All parts, percentages and proportions referred toherein and in the appended claims are by weight unless otherwiseillustrated. Physical test methods are described below:

[0128] Formulation and Melt Casting Details

[0129] All the ingredients except for sodium cocoyl isethionate,perfume, and triglycerides, are melted at 100 to 105 C and dissolved.Then sodium cocoyl isethionate is added slowly and dissolved bycontinuous mixing. Next the triglyceride(s) is added to the homogeneousmass. The mass is then allowed to cool to 70 to 90 C. at which time theperfume is added. Next the mass is then poured into molds and allowed tocool to 25 C. under ambient conditions.

EXAMPLE 1

[0130] Syndet toilet bars with and without lauryl alcohol as a phasestabilizer were melt cast from the formulations listed in table 1. BarsA and B are comparative using stearic acid as the structuring agent.Bars C and D represent embodiments of the present invention using12-hydroxystearic acid as the structuring agent. The bars were comparedfor melt phase stability, hardness, and mush using the test methodsdescribed below. Comparative bar A did not yield a homogeneous bar dueto phase separation. Comparative bar B containing lauryl alcohol as aphase stabilizer yielded a homogeneous bar but was considerably softerthan inventive bar D which contained the same amount of lauryl alcohol.Concentrations are given in parts. TABLE 1 Ingredients A B C D Sodiumcocoyl isethionate, f 25.00 25.00 25.00 25.00 Alfa Olefin Sulfonate, f9.00 9.00 9.00 9.00 Sodium Lauryl Ether 9.00 9.00 9.00 9.00 Sulfate (2EO), f Propylene Glycol, a,c 7.00 7.00 7.00 7.00 Glycerin, a,c 7.00 7.007.00 7.00 12-hydroxystearic acid — — 14.00 14.00 stearic acid (99%), b,d14.00 14.00 — — Sunflower Seed Oil a,d,e 25.00 25.00 25.00 25.00 Water4.00 4.00 4.00 4.00 Lauryl Alcohol, a,c — 10.00 — 10.00 Total 100.00110.00 100.00 110.00 Bar hardness (KPa) — 50 186 186 Rate of Wear 28.125.0 12.3 10.9 % Mush 39.8 28.1 34.7 24.7

EXAMPLE 2

[0131] The effect of replacing stearic acid (bar F) with12-hydroxystearic acid (bar E) was seen to improve bar hardness asillustrated in table 2. TABLE 2 E F Ingredients Inventive ComparativeSodium Cocoyl Isethionate, f 22.35  22.35  Stearic acid/ Palmitic Acid,b,d 5.88 5.88 Coco Fatty acid, b,d 0.59 0.59 Sodium Isethionate, f 0.500.50 Alfa Olefin Sulfonate, f 7.23 7.23 Sodium Lauryl Ether Sulfate (2EO), f 7.23 7.23 Perfume 1.25 1.25 Titanium Dioxide 1.00 1.00 PropyleneGlycol, a,c 5.00 5.00 Glycerin, a,c 4.00 4.00 Lauryl Alcohol, a,d 4.974.97 12-hydroxystearic acid 11.00  — stearic acid — 11.00  SunflowerSeed Oil, a,d,e 25.00  25.00  Water 4.00 4.00 100.00 100.00 Bar hardness0.20 MPa 0.116 MPa Rate of Wear 12.39% 19.05%

EXAMPLE 3

[0132] The effect of increasing the level of 12-hydroxystearic acid inthe inventive toilet bar was shown to improve mush properties, hardness,and to reduce the rate of wear as shown in table 3 and FIGS. 1 -3.Lather measurement of the different formulations indicates that there isno significant difference between the three formulations for lather.TABLE 3 Ingredients G H I J Sodium Cocoyl Isethionate, f 28.22 25.6624.10 23.00 Stearic acid/ Palmitic Acid, b,d 7.42 6.75 6.34 6.05 CocoFatty acid, b,d 0.75 0.68 0.64 0.61 Sodium Isethionate, f 0.63 0.57 0.530.51 Alfa Olefin Sulfonate, f 8.99 8.17 7.70 7.40 Sodium Lauryl EtherSulfate (2 8.99 8.17 7.7 7.40 EO), f Perfume 1.00 1.00 1.00 1.00Titanium Dioxide 1.00 1.00 1.00 1.00 Propylene Glycol, a,c 5.00 5.005.00 5.00 Glycerin. a,c 4.00 4.00 4.00 4.00 Lauryl Alcohol, a,d 5.005.00 5.00 5.00 12-hydroxystearic acid 5.00 10.00 13.00 15.00 SunflowerSeed Oil, a,d,e 20.00 20.00 20.00 20.00 Water 4.00 4.00 4.00 4.00 BarHardness (25° C.) kPa 127 228 279 279 Rate of Wear for 10 washes (%)11.92 7.22 5.51 — Mush (%) 26.77 25.63 22.11 —

[0133] Description of Test Methods:

[0134] Evaluation of Mush:

[0135] Immerse a weighed toilet bar in 250 ml water (at 25 C), in abeaker for four hours. Scrape the mush from the bar with a soft plasticknife. Weigh the scraped bar after allowing to dry at room temperature24 hours. The weight change multiplied by 100 and divided by the initialweight of the bar denotes the mush of the bar. Mush is calculated as theaverage of three bars.

[0136] Rate of Wear:

[0137] Wet a pre-weighed bar in running water and rotate 15 times whilein the tester's hand. Place on a support stand. Repeat 10 times at halfhour intervals. Weigh the washed bar after allowing to dry at roomtemperature for 16 hours. The weight change multiplied by 100 anddivided by the initial weight of the bar denotes the rate of wear of thebar.

[0138] Foam (Lather) Measurement:

[0139] A tester rotates a wet bar ten times between his hands. Then 5mls of 95 C water is added and the bar is rubbed with the hands togenerate lather. Then the tester dips his hands in a water tank under aninverted funnel coupled to a measuring cylinder so as to collect andmeasure the volume in mls of the generated lather.

[0140] Bar Hardness Measurement:

[0141] The method used for the hardness measurement is sectilometry orcutting the soap with a suitable wire as described e.g. by Bowen andThomas in Trans. Farad. Soc. 31, 164, (1935).

EXAMPLE 4

[0142] A syndet toilet bar “J” containing 40% by weight of sunflowerseed oil was melt cast from the formulation listed in table 4 and ahomogeneous bar was obtained with acceptable rate of wear and mushproperties. Ingredients % Sodium Cocoyl Isethionate  26.00 Stearic acid/Palmitic Acid  6.83 Coco Fatty acid  0.69 Sodium Isethionate  0.58Propylene Glycol  3.00 Glycerin  2.00 Lauryl Alcohol  2.0012-hydroxystearic acid  14.90 Sunflower Seed Oil  40.00 Water  4.00Total 100.00

[0143] While this invention has been described with respect toparticular embodiments thereof, it is apparent that numerous other formsand modifications of the invention will be obvious to those skilled inthe art. The appended claims and this invention generally should beconstrued to cover all such obvious forms and modifications which arewithin the true spirit and scope of the present invention.

What is claimed is:
 1. A toilet bar composition comprising: (i) about 5to 60% by weight of a liquid emollient with a melting point below 25 C;(ii) about 15% to 60% by weight of a surfactant; and (iii) more thanabout 5% by weight of 12-hydroxystearic acid, wherein the ratio of said12-hydroxystearic acid to said liquid emollient is in the range of about1 to 5 to about 10 to
 1. 2. The composition of claim 1 wherein the ratioof said 12-hydroxystearic acid to said liquid emollient is in the rangeof about 1 to 5 to about 2 to
 1. 3. The composition of claim 1 whereinsaid liquid emollient is selected from hydrophillic and hydrophobicliquid emollients, and blends thereof.
 4. The composition of claim 3wherein said liquid hydrophilic emollient is present in theconcentration range of about 2 to 20% by weight.
 5. The composition ofclaim 3 wherein said liquid hydrophilic emollient is present in theconcentration range of about 5 to 10% by weight.
 6. The composition ofclaim 3 wherein said liquid hydrophobic emollient is present in theconcentration range of about 2 to 45% by weight.
 7. The composition ofclaim 3 wherein the hydrophobic liquid emollient is present in theconcentration range of about 10 to 30% by weight.
 8. The composition ofclaim 3 wherein said hydrophilic liquid emollient selected frompolyhydric alcohols, polyols, saccharides, and mixtures thereof.
 9. Thecomposition of claim 3 wherein said hydrophobic liquid emollient isselected from triglycerides, hydrocarbons, silicones, fatty acids,fatty, esters, fatty alcohols, and blends thereof.
 10. The compositionof claim 1 wherein said concentration of 12-hydroxystearic acid is inthe range of about 5 to 20% by weight.
 11. The composition of claim 10wherein said concentration of 12-hydroxystearic acid is more than about10 to about 15% by weight
 12. The composition of claim 1 wherein saidsurfactant includes at least one acyl isethionate.
 13. The compositionof claim 12 wherein said at least one acyl isethionates are collectivelyin the concentration range of about 5 to about 45% by weight.
 14. Thecomposition of claim 12 wherein said at least one acyl isethionatesincludes sodium cocoyl isethionate.
 15. The composition of claim 1further comprising a solid emollient which is solid at 25 C.
 16. Thecomposition of claim 15 wherein said solid emollient is selected fromthe group of fatty acids, fatty esters, fatty alcohols, waxes, ortriglycerides.
 17. The composition of claim 15 wherein said solidemollient and said liquid emollient is in the ratio of about 1 to 10 toabout 10 to
 1. 18. The composition of claim 17 wherein said solidemollient and said liquid emollient is in the ratio of about 1 to 5 toabout 1 to
 2. 19. A toilet bar composition comprising: (i) about 5 to60% by weight of a liquid emollient with a melting point below 25 C;(ii) about 15% to 60% by weight of a surfactant; (iii) more than about5% by weight of 12-hydroxystearic acid, wherein the ratio of said12-hydroxystearic acid to said emollient is in the range of about 1 to 5to about 10 to 1; and (iv) less than about 15% by weight of water. 20.The composition of claim 19 wherein the ratio of said 12-hydroxystearicacid to said emollient is in the range of about 1 to 5 to about 1 to 3.21. The composition of claim 19 wherein the bar contains less than about6% by weight of water.
 22. A toilet bar composition comprising: a) about5 to 60% by weight of a liquid emollient with a melting point below 25C.; b) about 15% to 60% by weight of a surfactant; c) more than about 5%by weight of 12-hydroxystearic acid, wherein the ratio of said12-hydroxystearic acid to said liquid emollient is in the range of about1 to 5 to about 10 to 1; and d) a hydrophilic emollient, and ahydrophobic emollient; wherein the ratio of said hydrophilic emollientand said hydrophobic emollient is in the range of about 1 to 10 to about5 to
 1. 23. The toilet bar composition of claim 22 wherein the ratio ofsaid hydrophilic emollient to said hydrophobic emollient is in the rangeof about 1 to 8 to about 1 to
 5. 24. A toilet bar compositioncomprising: about 10 to 30% by weight of a triglyceride liquid emollientwith an iodine value in the range of 80 to 140 and a melting point below25 C.; about 15 to 60% by weight of an acyl isethionate; about 10 to 15%by weight of 12-hydroxystearic acid; and less than about 6% water.
 25. Atoilet bar composition comprising: a) about 5 to 60% by weight of ahydrophobic liquid emollient with a melting point below 25 C; b) about15% to 60% by weight of a surfactant; c) more than about 5% by weight of12-hydroxystearic acid, and wherein the ratio of said surfactant to saidhydrophobic liquid emollient is less than about 5 to
 3. 26. The toiletbar composition of claim 25 wherein the ratio of said surfactant to saidhydrophobic liquid emollient is in the range of about 10 to 1 to about 1to
 3. 27. The toilet bar composition of claim 25 wherein the ratio ofsaid surfactant to said hydrophobic liquid emollient is in the range ofabout 4 to 3 to about 1 to 2.